摘要：
A method of forming a golf ball includes forming a core using a 3D printer, and molding a cover in a surrounding position over the core through at least one of compression molding and injection molding. The core may be formed by printing a first core portion, printing a second core portion, and fusing the first core portion with the second core portion to form the core. Each of the first and second core portions may respectively include a plurality of concentric shells that are sequentially constructed.
技术问题语段：
The technical problem addressed in this patent is the need to produce golf balls with different play characteristics by using a 3D printing process. The invention relates to a method of forming a golf ball core using a 3D printer, and molding a cover over the core through at least one of compression molding and injection molding. The core is formed by printing a first core portion, printing a second core portion, and fusing the two core portions. The patent describes various methods for controlling the material composition of the cores to achieve the desired play characteristics.
技术功效语段：
The present invention relates to a golf ball with a unique core structure that is formed through a 3D printing process. The invention allows for the creation of golf balls with different play characteristics by balancing soft feel with good resilience in a multi-layer golf ball. The 3D printing process allows for the creation of golf balls with a unique structure that can achieve both high distance and control. The invention also includes a method for fusing the core and cover of the golf ball using a 3D printer. The technical effects of the invention include improved play characteristics, durability, and customization options for golf balls.
权利要求：
CLAIMS
1. A golf ball having a core and a cover, the golf ball formed by a process comprising:
forming the core by:
printing a first core portion including a first plurality of concentric shells;
printing a second core portion including a second plurality of concentric shells; and
fusing the first core portion with the second core portion to form the core;
molding the cover over the core such that the cover radially surrounds the core, the molding including at least one of compression molding and injection molding.
2. The process of claim 1, wherein fusing the first core portion with the second core portion includes:
placing the first core portion and second core portion in an opposing arrangement within a mold;
heating the mold to a temperature above the melting point of each of the respective first core portion and second core portion.
3. The process of any one of claims 1-2, wherein the spherical core has a diameter of from about 22 mm to about 42 mm; and
wherein each of the first plurality of concentric shells and the second plurality of concentric shells respectively include from about 9 shells to about 55 shells.
4. The process of any one of claims 1-3, wherein printing the first core portion and printing the second core portion each respectively include printing via fused filament fabrication.
5. The process of any one of claims 1-4, wherein the first plurality of concentric shells includes a first shell and a second shell; and wherein each of the first and second shells respectively have a homogeneous material composition; and
wherein the material composition of the first shell is different than the material composition of the second shell.
6. The process of any one of claims 1-5, wherein each of the first plurality of concentric shells is disposed at a different radial position within the first core portion; and
wherein printing a first core portion includes varying the material composition of each respective shell as a function of the radial position of that shell.
7. The process of any one of claims 1-6, wherein the first core portion includes a radially inward portion, a radially outward portion, and an intermediate portion that is radially disposed between the radially inward portion and the radially outward portion;
wherein printing the first core portion includes:
printing the radially inward portion using a first material; printing the radially outward portion using a second material; and printing the intermediate portion using a varying blend of the first material and the second material.
8. The process of any one of claims 1-7, wherein printing the second core portion includes depositing the second plurality of concentric shells onto the first core portion.
9. The process of any one of claims 1-8, wherein at least one of the first plurality of shells and at least one of the second plurality of shells is discontinuous.
10. A golf ball comprising:
a core formed from a plurality of concentric shells;
wherein the plurality of concentric shells includes:
a first set of concentric shells defining an inner portion of the core; a second set of concentric shells disposed radially outward from the first set of concentric shells, and defining an intermediate portion of the core; and
a third set of concentric shells disposed radially outward from the second set of concentric shells, and defining an outer portion of the core; and
a cover including a plurality of dimples, the cover disposed in a surrounding arrangement about the core, the cover formed through at least one of injection molding and compression molding; and
wherein the plurality of concentric shells includes from about 9 shells to about 55 shells.
11. The golf ball of claim 10, wherein the first set of concentric shells are formed from a first material;
wherein the third set of concentric shells are formed from a second material; and
wherein the second set of concentric shells are formed from a varying blend of the first material and the second material.
12. The golf ball of claim 1 1, wherein the blend of the first material and the second material that is used to form the second set of concentric shells varies as a function of a radial distance.
13. The golf ball of claim 11, wherein each shell of the first set of concentric shells, the second set of concentric shells, and the third set of concentric shells has a respectively homogenous material composition.
14. The golf ball of any one of claims 10-13, wherein the core further includes a homogenous inner core disposed radially interior to the first set of concentric shells.
15. The golf ball of claim 14, wherein the inner core is formed through injection molding, compression molding, or casting.
16. A method of making a golf ball comprising: printing a first core portion including a first plurality of concentric shells; printing a second core portion including a second plurality of concentric shells;
fusing the first core portion with the second core portion to form the core; and molding a cover over the core such that the cover radially surrounds the core, the molding including at least one of compression molding and injection molding.
17. The method of claim 16, wherein fusing the first core portion with the second core portion includes:
placing the first core portion and second core portion in an opposing arrangement within a mold;
heating the mold to a temperature above the melting point of each of the respective first core portion and second core portion.
18. The method of any one of claims 16-17, wherein each of the first plurality of concentric shells is disposed at a different radial position within the first core portion; and
wherein printing a first core portion includes varying the material composition of each respective shell as a function of the radial position of that shell.
19. The method of any one of claims 16-18, wherein the first core portion includes a radially inward portion, a radially outward portion, and an intermediate portion that is radially disposed between the radially inward portion and the radially outward portion;
wherein printing the first core portion includes:
printing the radially inward portion using a first material; printing the radially outward portion using a second material; and printing the intermediate portion using a varying blend of the first material and the second material.
20. The method of any one of claims 16-19, wherein the first plurality of concentric shells are printed in a sequential manner starting from a shell disposed at a most radially inward position.